DIY eBike and Powerwall

Haslero

New member
Joined
Sep 6, 2018
Messages
16
Hello battery freaks out there

I want to introduce myself to the forum. This is the first time ever i am writingsomething in a forum like that, i understand the benefits of swapping information regarding the same topics. I read a lot of stuff about batteries the last couple of weeksand how to safely handle them. I am scared but also fascinated about these cells and when you never risk something you will never get rewarded. I am 35 years old engineer and studied some mechatronics and machine tools stuff. So i have a little background in electronics, but not batteries. I did a lot of Rasperry and Arduino Projects and stuff like this.this is how i get here.

My first plan is to replace my car by a ebike (one full gas tank =, i will need a good battery for that bafang 1kw motor i ordered.
Second plan buy the house we are in, put a pv system on the roof and build a diy powerwall in my garage.
With the heat pump,pv system, powerwall and the ebike iwould be almost CO2 neutral. Would I?

i want to do this mostly with recycled batteries if i can, from a green view i like this idea very much.

Icollected about 150 cells and ordered 100 new Samsung INR18650-25E.Checkedall cells on capacity, self discharging and internal resistance and tried to decide which ones are the good and bad ones. not that easy than i thought it was. Does the internal resistance change over the battery lifetime? Is comparing the capacity with its original capacitya good indicator? Still a long way to go.

I alsomade a deal with an ebike shop and i can pick up their "old" ebike accumulators. go there tomorrow to get the first few.

thanks to all who share your information and journey through this secondstoragelife. and averagejoe and hppowerwall about their fantastic videos.
my way would be to spotweld the fuses to the battery :D. can i do that?i ordered also some of these chinese spotwelders. any bets how long it will last?
Is it also good to fuse every cell in the ebike battery? How would that work with the nickel strips?

one last question. i know theSamsung INR18650-25E isn't the best joice for that ebike batterie. but would it work with a 14s7p configuration and the bafang motor? 20A cont, 56A peak? The bbshd motorwould need 30A max. or am i wrong? Continous?

Also a few pics from my journey:
My DIY Lab, recycled cells and the 1kwh bike pack.

image_ppaeyv.jpg

image_qtuslq.jpg

image_xhuemk.jpg

Let me know your opinion. Thx.
 
Welcome and looks like you have a great start there.
 
Welcome - looks like you have a very solid start & bonus points for carbon neutral goals !
 
hbpowerwall said:
Welcome - looks like you have a very solid start & bonus points for carbon neutral goals !

Thank you very much.Many greets down under.

Now its getting colderand i realise that the powerwall needs to be even bigger for the wintertimes. Maybe 20kWh instead of 10. I will start slow. I have the time. Wantto be finish by summer 2020.

I willkeep you guys updated.
 
Haslero said:
Hello battery freaks out there

I want to introduce myself to the forum. This is the first time ever i am writingsomething in a forum like that, i understand the benefits of swapping information regarding the same topics. I read a lot of stuff about batteries the last couple of weeksand how to safely handle them. I am scared but also fascinated about these cells and when you never risk something you will never get rewarded. I am 35 years old engineer and studied some mechatronics and machine tools stuff. So i have a little background in electronics, but not batteries. I did a lot of Rasperry and Arduino Projects and stuff like this.this is how i get here.

My first plan is to replace my car by a ebike (one full gas tank =, i will need a good battery for that bafang 1kw motor i ordered.
Second plan buy the house we are in, put a pv system on the roof and build a diy powerwall in my garage.
With the heat pump,pv system, powerwall and the ebike iwould be almost CO2 neutral. Would I?

i want to do this mostly with recycled batteries if i can, from a green view i like this idea very much.

Icollected about 150 cells and ordered 100 new Samsung INR18650-25E.Checkedall cells on capacity, self discharging and internal resistance and tried to decide which ones are the good and bad ones. not that easy than i thought it was. Does the internal resistance change over the battery lifetime? Is comparing the capacity with its original capacitya good indicator? Still a long way to go.

I alsomade a deal with an ebike shop and i can pick up their "old" ebike accumulators. go there tomorrow to get the first few.

thanks to all who share your information and journey through this secondstoragelife. and averagejoe and hppowerwall about their fantastic videos.
my way would be to spotweld the fuses to the battery :D. can i do that?i ordered also some of these chinese spotwelders. any bets how long it will last?
Is it also good to fuse every cell in the ebike battery? How would that work with the nickel strips?

one last question. i know theSamsung INR18650-25E isn't the best joice for that ebike batterie. but would it work with a 14s7p configuration and the bafang motor? 20A cont, 56A peak? The bbshd motorwould need 30A max. or am i wrong? Continous?

Also a few pics from my journey:
My DIY Lab, recycled cells and the 1kwh bike pack.

image_ppaeyv.jpg

image_qtuslq.jpg

image_xhuemk.jpg

Let me know your opinion. Thx.

Freak meets other freaks ::) Hello to you too. Like you I studied Mechanical Engineering and was fascinated by Chemistry all my life. Finishing uni I did what most engineers do.. Work in IT.. Swapping coding for chemistry wasn't too bad.. Though I am loving this return to doing non coding work
 
Project Update:

Batteries:
Im waiting for all the material i ordered and dosome research regarding the BMS for the eBike battery.
Still no clue what the right one is except that it has to be14s 30A. Any tips are welcome. Are thereonly Batrium or the chinese ones? Anything between?
Daromer has some excellent explanation of active and passive BMS and i watched that video two times.

I also designed and printed somecell holders (there is some stuff one thingiverse, but i want to have it adjustable):

image_waczdw.jpgimage_bygwff.jpg


And i need more batteries...

Next:
Big day yesterday. Bafang BBSHD was delivered.

image_fvxsxm.jpg


Now i have to do some mechanical adaption on the bike... my research was a little bad on this. i learnedthat my bike has a pressfit bottom bracket ball bearing BBS92. And Bafang motors are designed forJIS and BSA standards. whatever that is.

but i knew i have to do some kind ofthis anyway. I printed some prototype parts to be sure everything is correct. Now i have to do them in steel.


image_avnlso.jpg

image_ynivhx.jpg


Keep you guys updated...
 
weeks go by.. and i did my first testride with my awsome bike. :idea:
details about the battery build can be found here:

https://secondlifestorage.com/t-sparks-all-over-the-place

next tasks:
forget the diy bike battery -> enjoy riding with a em3ev battery (wait 3 weeks) and concentrate on powerwalls?

or...

designing a new battrery case with the bms on top?

what would you do?
 
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